Method For Making An Outdoor Fireplace

ABSTRACT

A method for making a modular outdoor fireplace having textured exterior surfaces simulating natural stone or bricks and mortar. At least a fire-box unit and a chimney unit are cast from concrete with textured exterior surfaces. After placing the fire-box unit on a support surface, a fireplace insert is positioned in the fire-box unit and the chimney unit is supported either on the fire-box unit or on a cast concrete mantle which is first placed on the fire-box unit. The support surface may be a cast concrete hearth. A metal chimney is inserted through the chimney unit and the mantle and secured to the fireplace insert. A cast concrete cap is placed on the chimney unit.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

TECHNICAL FIELD

The invention relates to a method for making a modular outdoor fireplace from cast concrete components which simulate a natural stone exterior and a fireplace insert.

BACKGROUND OF THE INVENTION

Outdoor fireplaces have become increasingly popular either as a landscape feature or as part of an outdoor kitchen. However, construction of an outdoor fireplace has been labor intensive and consequently expensive. Typical outdoor fireplaces are constructed from brick, block or stone components which are custom built for each installation. In some cases, some of the fireplace components have been constructed at a manufacturing facility, while brick or stone veneer is manually applied at the jobsite.

BRIEF SUMMARY OF THE INVENTION

According to the invention, an outdoor fireplace may be quickly assembled from cast concrete components and a fireplace insert. Exterior surfaces of the cast concrete components may be shaped, textured and colored to simulate natural stones or bricks, thus eliminating the labor required to apply a stone or brick veneer to achieve a desired appearance. The cast concrete components used to construct the fireplace are a hearth, a fire-box unit, a mantle, a chimney unit and a chimney cap. A commercially purchased fireplace insert, chimney pipes and an optional spark arrester also are used in assembling the outdoor fireplace.

The fireplace can be quickly assembled at a jobsite by placing and leveling the hearth, placing the fire-box unit on the hearth, inserting the fireplace insert into the fire-box unit, positioning and securing the fireplace insert, placing the mantle on the fire-box unit, placing the chimney unit on the mantle, inserting the chimney pipes into the chimney unit and attaching the pipes to the fireplace insert, placing the chimney cap on the chimney unit, and securing the optional spark arrester to the chimney pipes, if used. Preferably, prior to stacking the concrete components, mortar is applied to the supporting concrete component. Any excess mortar after a component is installed may be removed.

In the simplest form, the outdoor fireplace may be constructed from only three components: a cast concrete fire-box unit, a purchased fireplace insert, and a cast concrete chimney unit. Visible exterior surfaces of the fire-box unit and the chimney unit are shaped and colored to simulate natural stones.

When a cast concrete hearth is used, one or more optional reference lines may be cast into the hearth. The reference lines outline the desired fire-box unit footprint area to aid in applying mortar between the fire-box unit and the hearth and to aid in aligning the fire-box unit on the hearth. One or more optional reference lines also may be cast in an upper surface of the mantle to aid in applying mortar to the chimney unit footprint area and to aid in alignment of the chimney unit on the mantle.

By casting the visible components of the outdoor fireplace from concrete, the molds impart a desired exterior appearance of stones or bricks. This eliminates the time and expense of applying stone or brick veneer to the cast concrete. It allows the outdoor fireplace to be assembled at the jobsite very quickly with minimal labor expense.

Various objects and advantages of the invention will become apparent from the following detailed description of the invention and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an outdoor fireplace constructed according to the invention;

FIG. 2 is a perspective view of a cast concrete hearth stone for the outdoor fireplace of FIG. 1;

FIG. 3 is a perspective view of a cast concrete fire-box for the outdoor fireplace of FIG. 1;

FIG. 4 is a fragmentary perspective view showing the fire-box being lowered onto the hearth;

FIG. 5 is a fragmentary perspective view showing the fireplace insert being lowered into the fire-box;

FIG. 6 is a fragmentary perspective view showing the fireplace insert positioned in the fire-box;

FIG. 7 is a fragmentary perspective view showing mortar being applied to the upper edge of the fire-box prior to placement of the mantle;

FIG. 8 is a fragmentary perspective view showing the mantle being lowered onto the top of the fire-box;

FIG. 9 is a fragmentary perspective view showing mortar being applied to an area on the mantle where the cast concrete chimney unit will be placed; and

FIG. 10 is a perspective view showing the chimney unit after it is placed on the mantle.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, an outdoor fireplace 15 constructed according to the invention is illustrated. The outdoor fireplace 15 is constructed from a number of components, most of which are cast from concrete and then assembled into the fireplace 15. When casting the concrete fireplace components, most of the exterior surfaces of the components are shaped to simulate natural stone blocks. The components forming the fireplace 15 consist of a cast concrete hearth 16, a cast concrete fire-box unit 17, a commercially purchased fireplace insert 18, a cast concrete mantle 19, a cast concrete chimney unit 20, a chimney cap 21, a metal chimney insert and a spark arrester.

The cast concrete components 16, 17, 19, 20 and 21 are cast in molds which texture the sides of the components to simulate natural stone. The hearth 16, the mantle 19 and the chimney cap 21 have flat top and bottom surfaces which facilitate stacking the components when assembling the outdoor fireplace 15, and have exposed side edges which simulate rough cut stone edges. The illustrated exposed sides of the fire-box 17 and the chimney unit 20 simulate cut and stacked rows of stone blocks. However, it will be appreciated that these side surfaces may have other visually pleasing appearances, such as simulating brick and mortar components. The tops and bottoms of the fire-box 17 and the chimney unit 20 are flat to facilitate stacking when assembling the outdoor fireplace 15. It should be appreciated that the concrete used to construct these components may be colored or the surfaces may be stained to simulate natural stone blocks, or bricks, etc.

The fireplace insert 18 is a commercially available product designed for indoor or outdoor fireplaces. Typically, it will be made from metal and lined with a suitable refractory material which will withstand heat from the fire and will reflect heat out of a side opening. Preferably, the fireplace insert 18 is constructed from stainless steel to reduce corrosion when exposed to rain, snow and high outside humidity. The fireplace insert 18 will typically come with a grate 24 for holding firewood.

FIG. 2 shows the hearth 16. As shown in dotted lines, the hearth 16 may have an optional lower portion 25 which will be embedded in the ground and will not be visible after the hearth 16 is placed in its final position. This thickened portion will add stability to the fireplace. Since the hearth can act as a structural foundation for the fireplace, reinforcements may be embedded in the hearth. As a first step in constructing the outdoor fireplace 15, a level foundation is prepared and the hearth 16 is set in its final place. When the hearth 16 is cast, recesses 27 may be formed in a top surface 28 of the hearth 16 and lifting hooks 29 embedded in the concrete located in the recesses 27. For installing the hearth 16, chains or cables (not shown) are secured to the hooks 29 and the hearth 16 is lifted and set in its final position using construction equipment such as a crane, or a front end loader or a forklift (not shown). Workers may guide and orient the hearth 16 as it is lowered into its final position.

After the hearth 16 is set in place, mortar 30 is manually applied to a footprint area where the fire-box 17 will sit on the hearth 16. Optionally, lines (not shown) may be drawn or embedded in the hearth top surface marking the fire-box footprint area to facilitate application of the mortar. One or more alignment lines 31 also may be provided to facilitate placement of the fire-box unit 17 on the hearth 16. The alignment line 31 and the lifting hook recesses 27 are located where they will not be visible when the outdoor fireplace 15 is assembled.

Details of the cast concrete fire-box unit 17 are shown in FIG. 3. The fire-box unit 17 is generally a hollow rectangular box having a top opening 34, a front opening 35 and a bottom opening 36. The fire-box unit 17 has a flat lower edge 37 that forms the footprint area which rests on the hearth 16 and is secured in place with the mortar 30, and has a flat upper edge 38 on which the mantle 19 is placed. Lifting hooks (not shown) may be embedded in the concrete in the interior of the fire-box unit 17. Chains or straps 39 are temporarily secured to the hooks to facilitate lifting the fire-box unit 17 onto a truck for transportation and for setting the fire-box unit 17 on the hearth 16.

FIG. 4 shows the fire-box unit 17 being placed on the previously set hearth 16. The fire-box unit 17 is lifted, for example, by a lifting equipment (not shown) secured to the chairs or straps 39, and lowered onto the hearth 16. Workers (not shown) guide the fire-box unit 17 as it is lowered so that it is properly positioned on the hearth 16. The optional guide line 31 can help in positioning the fire-box unit 17. The workers then remove any excess mortar 30 from the hearth 16.

After the fire-box unit 17 is set on the hearth 16, the fireplace insert 18 is lifted using straps 40 and lowered into the fire-box unit through the top opening 34, as shown in FIG. 5. Again, the workers help guide the fireplace unit 18 into the fire-box unit 17. The fireplace insert will be positioned inside the fire-box unit 17 and will rest on the hearth 16. Typically, the fireplace insert 18 will have some tabs (not shown) which can be used for securing the fireplace insert 18 in the fire-box unit 17. The workers will align the fireplace insert 18 with the front opening 35, as shown in FIG. 6, and then secure the fireplace insert to the fire-box unit 17 with masonry screws (not shown).

The workers will then apply a thin layer of mortar 41 to the upper edge 38 of the fire-box unit 17, as shown in FIG. 7, and then the mantle 19 is lifted and placed on the fire-box unit 17, as shown in FIG. 8. Again, workers guide the mantle 19 as it is lowered onto the fire-box unit 17 to assure that it is properly positioned. It will be noted that there is a central opening 42 cast in the mantle 19 for passing the chimney insert 22. The opening 42 will align with a flange or other configuration for securing the chimney insert 22 to the fireplace insert 18.

Prior to setting the chimney unit 20 on the mantle 19, mortar 43 is applied to the mantle in a footprint area where the chimney unit 20 will rest, as shown in FIG. 9. The mantle 19 also may include one or more alignment lines 44 to facilitate positioning the chimney unit 20 on the mantle 19. Preferably, any alignment lines 44 will be located where they will be just covered by the chimney unit 20. Using chains or straps 45, the chimney unit 20 is lowered onto the mantle 19, as shown in FIG. 10. Workers will help guide and position the chimney unit 20 on the mantle 19 as it is lowered. Once the chimney unit 20 is in place, the workers will remove any excess mortar 43 from the mantle 19.

After the chimney unit 20 is placed on the mantle 19, the workers will install the chimney insert 22. The chimney insert 22 may be, for example, two concentric metal pipes. The workers may use ladders (not shown) or may stand on the mantle and lower the metal pipes through the top of the chimney unit 22 until they engage flanges or other fittings (not shown) on the fireplace insert 18. The chimney insert 22 serves to protect the concrete in the mantle 19 and the chimney unit 20 from excessive heat. Mortar may then be applied to the top of the chimney unit 20 and the chimney cap 21 (FIG. 1) is then set on top of the chimney unit 20.

Finally, an optional rain deflector or a spark arrester 23 may be placed on the top of the chimney insert 20. Once the assembly is completed, the outdoor fireplace 15 is ready for use.

Since the outdoor fireplace components are all manufactured prior to delivery to the jobsite and simply assembled at the jobsite, the outdoor fireplace can be constructed and used the same day. The method for making an outdoor fireplace eliminates the long time and expense required in the past for assembling the fireplace components and then applying bricks or stones to the surface to finish the fireplace.

The illustrated outdoor fireplace 15 is a preferred embodiment of the invention. It will be appreciated that for a lower cost outdoor fireplace, the hearth 16 and the mantle 19 may be omitted. Here, the fire-box unit could be set on packed gravel or on a poured concrete base or on paving blocks. It also should be appreciated that the mantle 19 could be cast as an integral part of either the fire-box unit 17 or the chimney unit 20. This would eliminate the separate step of installing the mantle 19. Further, the chimney cap 21 could be cast as an integral part of the chimney unit 20, or could be replaced with metal flashing

As used herein, the term “mortar” includes a cement based material or other adhesives suitable for use for bonding together concrete components.

It will be appreciated that various modifications and changes may be made to the above described preferred embodiments of a method for making an outdoor fireplace without departing from the scope of the following claims. 

1. A method for making an outdoor fireplace comprising the steps of: a) casting a fire-box unit and a chimney unit from concrete where said fire-box unit and said chimney unit have a finished exterior surface texture selected from the group consisting of simulated natural stone or simulated bricks and mortar; b) placing the fire-box unit on a support surface; c) inserting a fireplace insert into the fire-box unit; and d) positioning the chimney unit above the fire-box unit where the chimney unit is supported on the fire-box unit.
 2. A method for making an outdoor fireplace, as set forth in claim 1, and further including the step of positioning a metal chimney insert to extend downwardly through the chimney unit to the fireplace insert.
 3. A method for making an outdoor fireplace, as set forth in claim 1, and further including the steps of casting a concrete hearth, positioning the cast hearth to form said support surface, wherein said fire-box unit defines a footprint area on the support surface when placed on the support surface.
 4. A method for making an outdoor fireplace, as set forth in claim 3, and including the step of placing at least one mark on the hearth to identify a desired location of the footprint area to facilitate placement of the fire-box unit on the hearth.
 5. A method for making an outdoor fireplace, as set forth in claim 3, and including the steps of placing marks on the hearth to mark the location of the footprint area, and applying mortar to the marked location prior to placing the fire-bon on the hearth.
 6. A method for making an outdoor fireplace, as set forth in claim 3, and further including the steps of casting a concrete mantle, positioning the mantle on an upper edge of the fire-box unit wherein the mantle is supported on the fire-box unit; and positioning the chimney unit on the mantle, wherein the chimney unit and the mantle are supported on the fire-box unit.
 7. A method for making an outdoor fireplace, as set forth in claim 6, and including the step of placing marks on the upper surface of the mantle to identify at least a portion of the area where the chimney unit will be supported on the mantle.
 8. A method for making an outdoor fireplace, as set forth in claim 6, and including the steps of applying mortar to the upper edge of the fire-box unit prior to positioning the mantle on the fire-box unit, and applying mortar to the upper surface of the mantle prior to placing the chimney unit on the mantle.
 9. A method for making an outdoor fireplace, as set forth in claim 6, and further including the step of passing a chimney insert downwardly through openings in the chimney unit and the mantle and securing the chimney insert to the fireplace insert.
 10. A method for making an outdoor fireplace, as set forth in claim 9, and further including the step of placing a chimney cap on a top of the chimney unit, said chimney cap having an opening through which the chimney insert passes.
 11. A method for making an outdoor fireplace, as set forth in claim 10, and further including the step of mounting a spark arrester on an upper end of the chimney insert.
 12. A method for making an outdoor fireplace, as set forth in claim 1, and further including the steps of casting a concrete mantle; positioning the mantle on the upper edge of the fire-box unit and positioning the chimney unit on such upper surface area, wherein the chimney unit and the mantle are supported on the fire-box unit.
 13. A modular outdoor fireplace comprising a cast concrete hearth having textured edges, a hollow cast concrete fire-box unit having textured exterior surfaces mounted on said hearth, said fire-box unit having at least an open top and a front opening, a fireplace insert positioned in said fire-box unit and having a front opening aligned with the front opening on said fire-box unit, a cast concrete mantle mounted on the top of said fire-box unit, said mantle having a chimney opening aligned with a chimney opening on said fireplace insert, a cast concrete chimney unit having textured exterior surfaces mounted on said mantle, a chimney cap mounted on said chimney unit, said chimney cap having a chimney opening, and a chimney insert passing from said fireplace unit through said mantle opening, said chimney unit and said chimney cap.
 14. A modular outdoor fireplace, as set forth in claim 13, and wherein said exterior surfaces of said fire-box unit and said chimney unit are textured to simulate stone blocks.
 15. A modular outdoor fireplace, as set forth in claim 14, and wherein said hearth, said mantle and said chimney cap have exterior edges which are textured to simulate stone blocks. 